Subject: Subject Code:

PLC & AUTOMATION

PBL PROJECT ASSIGNMENT

TITLE OF PROBLEM: DESIGN & DEVELOPMENT OF SAFETY DOOR

CONTROLLER USING PLC

DURATION OF PROBLEM: 6 WEEKS

BASE SUBJECT: PLC & AUTOMATION

POSSIBLE INTEGRATION WITH THE FOLLOWING SUBJECT:

DIGITAL ELECTRONICS & SYSTEM

1. OUTCOMES
Knowledge Process
1. Design and develop a safety door 1. Able to use programming software
controller using PLC to modify internal registers, perform
2. Integrate the program with input/output tasks and compile
hardware and software programming codes.
3. Analyze and evaluate the 2. Able to conduct and control sensors
performance of the system. and actuators.
3. Able to simulate the programs built
with a simulation software and
determine the success of the
program
4. Able to design an algorithm on how
to solve the design problem.

2. PROFILE OF STUDENTS

Subject of Study: PLC & AUTOMATION

Year of Study: 3rd Year

Number of Students: 71

Nature of Groups: 5-6 students per group

3. PRIOR KNOWLEDGE & SKILLS

Digital Electronics, Ladder Programming, Sensors and Actuators.

4. NEW INTEGRATED LEARNING ISSUES

1) Students able to design the algorithm and integrate the program with the hardware
2) Able to analyze and evaluate the performance of the system.
5. PROBLEM SCENARIO

GlaxoSmithKline (GSK) is one of the leading pharmaceutical companies in Malaysia.

GSK is a British based company producing healthcare, pharmaceutical and biological
products with strong reputation on research and development (R&D) of broad range of
pharmaceutical products covering anti infection, respiratory, metabolic, oncology and
vaccines. GSK has been operating in the country for more than 50 years and today
employs close to 600 people in its main facilities based in Ampang, Kuala Lumpur.

Due to the nature of the business, the company decides on employing a safety door in
their inventory facilities. Since there are many options available such as sectional up-
and-over type, non protruding type, retractable up-and-over and so on, the facility
manager decided to outsource the project to local company for design and assembly to
get the best deal.

As one of the bidding company, you are given the following restrictions in your design:
1. The door must have manual buttons on both side of the door (inside and outside)
as well as remote control button
2. The button should have the capability to stop the door midway and continue to
operate in another direction after the second push.

3. There should be mechanisms installed at each end of the door to prevent any
motion overdrive
4. Light beams must be installed across the bottom of the door. Any breakage when
the door closes will stop and reverse the motion of the door.
 5. Informational light should be installed and operates for some time after the door
opens or closes.

The facility manager requires full report on your design and you should be able to
produce a miniature prototype for the bidding.

6. FILA/KNL CHART
Ideas/Need to
Facts/Knowledge Learning Issues Action Plan
Know

• PLC as main • Type of • How to • Week 8

controller door build the Group setting &
door? Problem
• How to Identification
integrate
components • Week 9
? Team discussion
• & Self-directed
learning

• Week 10
Team discussion
& self-directed
learning

• Week 11
Synthesis &
Application

• Week 12
Synthesis &
Application

• Week 13
Closure/Reflection

7. ASSESSMENT PLAN
Tool Individual/ Formative/ Weightage Assessed by
Group Summative

Demo (rubric) Individual 5%

Technical Group 13%
Report/Log
Report (rubric)

Peer-to-peer Individual 2%
review
Instructor
(rubric)

8. FOLLOW-UP AFTER PROBLEM REVIEW

Action Taken:
Followed Up by:

9. PROBLEM-CRAFTING TEAM

Name:
1.